U.S. patent application number 15/740308 was filed with the patent office on 2018-07-05 for device for covering a floor pan of a motor vehicle and method for producing the device.
The applicant listed for this patent is AUTONEUM MANAGEMENT AG. Invention is credited to Mathias KOSSANYI.
Application Number | 20180186265 15/740308 |
Document ID | / |
Family ID | 53540643 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180186265 |
Kind Code |
A1 |
KOSSANYI; Mathias |
July 5, 2018 |
DEVICE FOR COVERING A FLOOR PAN OF A MOTOR VEHICLE AND METHOD FOR
PRODUCING THE DEVICE
Abstract
The present invention is directed to a device for at least
partially covering a vehicle floor pan of a motor vehicle,
comprises a carrier element made at least by a hard foam material,
a vibration decoupling element made at least by a soft foam
material, a surface layer to visually cover the device from the
top, wherein the device has a shield element, which is made at
least by a plastic material and is configured for accepting,
absorbing and distributing the energy of a localized impact stress,
which is applied on the device from above against the shield
element. The present invention is also directed to a method for
producing the device.
Inventors: |
KOSSANYI; Mathias; (Paris,
FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AUTONEUM MANAGEMENT AG |
Winterthur |
|
CH |
|
|
Family ID: |
53540643 |
Appl. No.: |
15/740308 |
Filed: |
June 29, 2016 |
PCT Filed: |
June 29, 2016 |
PCT NO: |
PCT/EP2016/065101 |
371 Date: |
December 27, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 44/588 20130101;
B32B 2307/72 20130101; B29K 2023/12 20130101; B32B 2605/08
20130101; B29K 2995/0091 20130101; B32B 5/32 20130101; B29C 39/00
20130101; B29C 44/1214 20130101; B32B 2262/0276 20130101; B32B
2266/08 20130101; B32B 5/142 20130101; B32B 2605/003 20130101; B29C
44/1228 20130101; B32B 2262/0253 20130101; B32B 2266/06 20130101;
B32B 2307/536 20130101; B32B 2307/102 20130101; B29K 2995/0002
20130101; B29K 2075/00 20130101; B29K 2995/007 20130101; B32B
2266/025 20130101; B32B 5/18 20130101; B32B 5/022 20130101; B32B
2266/0278 20130101; B29C 44/1285 20130101; B29K 2105/045 20130101;
B29L 2031/3017 20130101; B32B 27/40 20130101; B29C 67/246 20130101;
B32B 3/02 20130101; B32B 5/145 20130101; B60N 3/048 20130101; B32B
2266/0228 20130101; B32B 2307/748 20130101; B32B 2471/00 20130101;
B32B 27/12 20130101; B32B 2307/56 20130101; B32B 7/06 20130101;
B32B 3/26 20130101; B60R 13/0815 20130101; B29K 2105/04 20130101;
B32B 5/245 20130101; B32B 27/065 20130101 |
International
Class: |
B60N 3/04 20060101
B60N003/04; B32B 5/18 20060101 B32B005/18; B32B 5/32 20060101
B32B005/32; B32B 27/06 20060101 B32B027/06; B32B 27/40 20060101
B32B027/40 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 6, 2015 |
EP |
15175557.6 |
Claims
1. A device adapted for at least partially covering a vehicle floor
pan of a motor vehicle, comprising a carrier element made of at
least a hard foam material, a vibration decoupling element made of
at least a soft foam material, a surface layer to visually cover
the device from the top, wherein the device has a shield element
made of at least a plastic material and is configured for
accepting, absorbing, and distributing the energy of a localized
impact stress, which is applied on the device from above and
against the shield element.
2. The device according to claim 1, wherein at least the carrier
element and the shield element are connected by the soft foam
material, which forms the vibration decoupling element.
3. The device according to claim 1 or wherein the shield element is
placed above the upper side of the carrier element and supported by
the same in case of the impact.
4. The device according to claim 1, wherein the shield element has
a border section, which is supported by at least one support region
of the carrier element.
5. The device according to claim 1, wherein the shield element has
at least one passage section configured for allowing the soft foam
material to pass through at least a part of the shield element
during production of the device.
6. The device according to claim 1, wherein the carrier element has
at least one passage section, which is vertically aligned with the
at least one passage section of the shield element.
7. The device according to claim 1, wherein the carrier element has
at least one empty compartment, which is accessible for being
entered by the soft foam material during production of the
device.
8. The device according to claim 7, wherein the shield element is
at least in part covering the at least one empty compartment.
9. The device according to claims 5, wherein the at least one
passage section of the shield element and the at least one empty
compartment are configured to allow the soft foam material pass the
second passage section and to at least partially enter the empty
compartment during production of the device, wherein the empty
compartment, in particular, serves as a degassing space for the
soft foam material.
10. The device according to claim 5, wherein the at least one
passage section of the carrier element, the at least one passage
section of the shield element and the at least one empty
compartment are configured to allow the soft foam material to
subsequently pass at least one passage section of the carrier
element, at least one passage section of the shield element, then
preferably a channel section of the shield element, then at least
one second passage section of the shield element and to finally at
least partially enter the empty compartment during production of
the device, wherein the empty compartment, in particular, serves as
a degassing space for the soft foam material.
11. The device according to claim 1, wherein the shield element
comprises at least two passage sections, which run substantially
vertical through the shield element, and at least one channel
section, which runs substantially non-vertically, in particular
horizontally along the shield element and which connects the at
least two passage sections.
12. The device according to claim 1, wherein the shield element is
configured to serve as a support and impact zone for the support
bar of a child seat in a motor vehicle.
13. A method for producing a device for at least partially covering
a vehicle floor pan of a motor vehicle, comprising: providing a
carrier element made at least by a hard foam material; providing a
vibration decoupling element made at least by a soft foam material;
providing a surface layer to visually cover the device from the
top; providing a shield element, which is made at least by a
plastic material and is configured for accepting, absorbing and
distributing the energy of a localized impact stress, which is
applied on the device from above against the shield element; and
assembling said components for providing the device.
14. The method according to claim 13, including the step of
applying a reaction injection molding process to provide the
vibration decoupling element, and, preferably to connect at least
two or all of the components of the device.
15. A method of using, the device according to claim 1 for
supporting the stand of a child seat in a motor vehicle, in
particular in the case of a crash of the motor vehicle.
Description
TECHNICAL FIELD
[0001] The present invention is directed to a device for at least
partially covering a vehicle floor pan of a motor vehicle and
method for producing the device.
BACKGROUND ART
[0002] In the car industry, such devices for covering a floor pan
fulfil several functions. Any unevenness of the vehicle floor pan
should be evened out by the device for providing a flat surface
layer, which is used to support the feet of the passengers. The
noise, which is emitted by the floor pan, should be dampened in a
sufficient quality and quantity. Moreover, such a device should be
possibly light-weight and be producible in a cost-efficient manner.
Therefore, such devices are usually adapted to at least meet the
requirements of a predetermined technical specification list, which
is provided by a car producer for the producer of the device.
Typical devices for covering a floor pan are adapted to meet the
requirement for providing sufficient mechanical loading capacity
for carrying the feet of passengers. The device of the present
invention should be able to have another specific property, which
is the capability to accept, absorb and distribute the energy of a
localized impact stress, which is applied on the device from above
against the device. Such a case typically occurs when the backrest
of a rear-facing baby seat, which is mounted on a car seat or car
bench, e.g. by an ISOFIX system, has to be supported by a stand on
the floor device for guaranteeing the positioning of the baby seat
even in the case of a car crash. In a car crash, a localized impact
stress will act on the floor device at the position, where the
backrest is supported on the floor by a stand or socket. Normal
devices for supporting the feet of passengers, which are not
configured to withstand the impact forces, would deform under the
extreme forces of a localized impact stress and would not fulfil
the safety requirements.
SUMMARY OF THE INVENTION
[0003] It is the object of the present invention to provide a
device for at least partially covering a vehicle floor pan of a
motor vehicle and method for producing the device, wherein the
device has a loading capacity to sufficiently withstand an
increased mechanical load.
[0004] The problem is solved by the device of claim 1 and the
method according to claim 13. Preferred embodiments are subject
matters of the dependent claims and can be derived from the present
description of the invention and the drawings.
[0005] The device according to the invention for at least partially
covering a vehicle floor pan of a motor vehicle, comprises a
carrier element made at least by a hard foam material, a vibration
decoupling element made at least by a soft foam material, a surface
layer to visually cover the device from the top, wherein the device
has a shield element, which is made at least by a plastic material
and is configured for accepting, absorbing and distributing the
energy of a localized impact stress, which is applied on the device
from above against the shield element.
[0006] The implementation of a shield element containing a plastic
material in combination with a carrier element containing the hard
foam material offers substantial improvement of the mechanical
stability of the device against localized impact stress, which is
applied on the device from above against the device. The device and
the shield element are configured to accept the impact energy,
which means that other components of the device, e.g. the carrier
element, are protected from being directly and fully hit by the
impact. The shield element absorbs a part of the impact energy,
e.g. by being configured to deform by a limited amount under a
predetermined maximum impact load. Additionally, the shield element
is configured to distribute a part of the impact load to the
carrier element, which is achieved in particular by providing a
sufficiently stable carrier element and a sufficiently large
support region of the carrier element, where the shield element is
supported and carried by the carrier element. The shield element
distributes the localized impact load, originating from a smaller
impact area, to a larger support area at the carrier element.
Compared to conventional devices, the device according to the
invention may have a slightly increased mass due to the use of the
highly resistive shield element. However, the additional mass also
may be beneficial because such a shield element may additionally
contribute to the mass of a vibration decoupling system, which is
configured as a mass-spring system, wherein the sound absorbing
element acts as the spring, the shield element thereby improving
the sound insulating properties of the device.
[0007] The carrier element contains at least a hard foam material
or substantially consists from said material. The hard foam
material can be open-cell, and is preferably closed-cell.
[0008] The hard foam material, preferably, is a low density
cellular material for instance at least one of expanded
polypropylene (EPP), expanded polyethylene (EPE), expanded
polystyrene (EPS) or a mixture of EPS and EPE, commercially known
as Piocelan, or rigid polyurethane (rigid PUR) or a combination of
these materials. The hard foam material, preferably, is a
polystyrene foam, and preferably is expanded polystyrene foam
(EPS). Such a material is rigid and sufficiently stable under
mechanical load, e.g. when receiving the energy distributed by the
shield element.
[0009] The carrier element, preferably is an integral part, but may
also be composed of separate parts, which are preferably
interconnected to form the carrier element. The carrier element may
have a substantially planar plate section, which provides an
appropriate support for a substantially planar shield element.
However, the plate section may at least in part deviate from an
ideally planar shape. The plate section may have at least one
opening or recess, which may reduce the weight. Moreover, an
opening may be configured to form a support frame, which acts as a
support region for supporting the border region of a shield
element. Preferably, the carrier element has projections, which
extend preferably vertically downward from the plate section, with
an empty space between the projections, which may be partly filled
with the soft foam material, in particular the soft foam material
of the vibration decoupling element. Such a setup provides
sufficient light-weight to the device and sufficient mechanical
loading capacity. The projections may also be hollow, and may, in
particular be formed as domes, i.e. the projections have a
substantially conical shape, which preferably tapers downward in
the direction of the floor pan.
[0010] The projections, in particular domes, are preferably evenly
spread over the entire surface of the device that would be in
contact with the floor pan. By using this shape the contact to the
floor pan and the overall weight distribution would be more evenly
spread. The dome shape used is preferably a low pitched, shallow
dome that is described geometrically as having a circular base and
a segmental section. In addition a dome shape is less critical in
the fitting of the floor covering on the floor pan. The conical
feet have a straight and narrow surface area where the part is in
contact with the floor pan. A miss match of the feet with the floor
will cause the floor pan to wobble. In case of the dome shaped
protrusion the shape will easier follow slight differences due to
its shape.
[0011] The vibration decoupling element contains at least a soft
foam material or is substantially consists from said material. The
soft foam material can be closed-cell, and is preferably open-cell,
which improves the sound absorbing properties. The soft foam
material, preferably, is polyurethane foam (PUR foam). For
instance, polyurethane foam with a density between 30 and 90
kg.m.sup.-3 is used for the soft foam material. Such a foam has the
benefit of providing superior flow properties when flowing along
the carrier element in a process of producing the vibration
decoupling element by a reaction injection moulding process step.
The vibration decoupling element may be an integral part or may be
composed of separate parts. The vibration decoupling element, in
particular the whole device, may be produced by a one-step foam
reaction injection moulding process. Preferably, the soft foam
material of the vibration decoupling element covers the carrier
element at least in part, or preferably substantially completely
surrounds at least a part of--or substantially completely--the
carrier element and/or the shield element. Preferably, the soft
foam material of the vibration decoupling element covers at least
the bottom section of the carrier element, which is configured to
face and contact the floor pan. This way, the vibration decoupling
element acts as the spring in a mass-spring sound insulation
system.
[0012] The device may have exactly one shield element or, if
required, more than one shield element. The shield element contains
a plastic material or substantially consists from said material,
which provides the required impact loading capability. The plastic
material may be a thermoplast, in particular polypropylene (PP),
polyester, e.g. polyethylene terephthalate (PET) or polybutylene
terephthalate (PBT), or polyamide, e.g. PA6 or PA66. The plastic
material may contain a filler, which may provide additional
mechanical stability to the shield element. Such a filler may be or
may contain talcum, which improves stiffness in terms of the
E-Modulus, the thermal conductivity, the impact strength and
chemical resistance of the plastic material, which is particularly
beneficial for the present purpose to resist an impact load. For
example, PP T20 is appropriate to be used for the shield element.
The filler may also be or may contain fibers, e.g. short fibers,
thereby forming a fiber-reinforced plastic material. Such fibers
may be glass fibers. Glass fiber-reinforced plastic, in particular
glass fiber-reinforced polypropylene, has improved dimensional
stability, resistance to warpage, rigidity and strength. For
example, PP-GF50 or PA-GF50 are appropriate to be used for the
shield element.
[0013] The shield element may be a plate or contain a plate, e.g. a
plate section. Such a plate preferably is planar. The shield
element may be arranged at least in part or substantially
completely between the carrier element and the surface layer. The
shield element may be arranged at least in part or substantially
completely within a receiving space inside the carrier element. The
shield element may be supported in direct contact with the carrier
element or in indirect contact, wherein in the latter case another
layer of material, e.g. parts of the sound absorbing element, may
be disposed between the shield element and the carrier element, as
long as the carrier element receives the major part of an impact
energy, distributed by the shield element. A border region of the
shield element may be supported by at least one support region of
the carrier element. The border region and/or the at least one
support region may be reinforced by an additional reinforcement
material, e.g. a metal part or metal frame, preferably
aluminium.
[0014] The shield element may include a rib section, which may form
a plate or plate section of the shield element. The rib section may
also be provided in addition with a plate, in particular integrally
formed with the latter. The rib section may comprise a plurality of
ribs, which. Preferably, are interconnected to form a grid layer or
grid structure, e.g. a grid layer. The grid may be basically
tetragonal, trigonal, hexagonal or cubic. This way, additional
stiffness and mechanical loading capability is provided to the
shield element.
[0015] The mechanical loading capability against an impact stress
can be tested using the following method, for example: an impact
socket is placed on top of the device according to the invention or
on top of the shield element of the device. The contact area
between the socket and the target is 80 mm.times.80 mm or a circle
with a 90 mm diameter. A pressure cylinder is pressed from atop
against the socket, e.g. using a mandrel screw spindle. The
pressure system should be capable to increase the load from zero to
a maximum load value within a short time period, in order to
simulate an impact load. The time period, during which a constant
maximum load is applied, is preferably 100 milliseconds (ms),
wherein the force my initially continuously increase, e.g. during a
ramp of 25 ms, before reaching the maximum load value, and may
subsequently continuously decrease, e.g. during a rampe of 60 ms,
before reaching again zero pressure. The maximum load value is
between 650 and 900 deca-Newton (daN) and is preferably 700 daN or
800 daN. The shield element and/or the device, preferably, is
configured to withstand an impact load between 600 daN and 900 daN,
in particular of 700 daN or 800 daN. The measurement system should
be capable of monitoring the maximum deflection of the target, e.g.
the shield element or the surface layer of the device. This can be
achieved by a optically monitoring using a high-speed camera. The
specification of the shield element may include that the deflection
does not exceed a predetermined displacement value of the deflected
target. Such a displacement may be, e.g. 40 mm or 50 mm. This way,
it can be guaranteed that the backrest of a baby seat, including
the baby or child, would be sufficiently supported by the device
including the shield element.
[0016] Preferably, at least the carrier element and the shield
element, preferably also the carpet, are connected by the soft foam
material, which forms the vibration decoupling element. However,
said components may also be interconnected or adhered differently.
A sheet member may be placed under the carpet, which in particular
is a tufting carpet or a nonwoven carpet, in order to prevent
bleeding-through of the soft foam raw material of the vibration
decoupling element during a step of reaction injection molding. To
prevent foam strike through in the top surface layer, an additional
sheet member, e.g. a fibrous nonwoven or textile layer, can be
placed under the surface layer. This additional layer should be
chosen such that the foam will be hampered in its flow. Preferably
this layer is one of a polyester or polyolefin, polypropylene or
polyethylene, nonwoven. The layer can be made of staple fibres or
of continuous filament material. Binder can be used when
necessary.
[0017] Preferably, the shield element is placed above the upper
side of the carrier element and supported by the same in case of
the impact. This way, the full height of the carrier element can be
used to withstand the impact. Preferably, the shield element is
supported by parts of the carrier element, which are positioned
beneath the shield element, thereby supporting also central regions
of the shield element. However, it is also preferred that only a
border region of the shield element is supported by the carrier
element. The shield element may partly or fully be inserted inside
the carrier element or inside the volume, which is delimited by the
surface enveloping the carrier element. Thereby, the device becomes
more com pact.
[0018] Preferably the shield element has a border section, which is
supported by at least one support region of the carrier
element.
[0019] Preferably, the shield element has at least one passage
section configured for allowing the soft foam material to pass
through at least a part of the shield element during production of
the device. This allows to more homogeneously and efficient
distribute the foam raw material through the shield element and/or
to connect the shield element at least with the vibration
decoupling element.
[0020] Preferably, the carrier element has at least one passage
section, which is preferably vertically aligned with the at least
one passage section of the shield element. This way, the foam can
be distributed through both, the barrier element and the shield
element, which is useful, in particular, during a one-step reaction
injection molding process.
[0021] Preferably, the carrier element has at least one empty
compartment, i.e. air filled compartment, which is accessible for
being entered by the soft foam material during production of the
device. Such an empty compartment has the advantage that the foam
can enter and expand inside the empty compartment, thereby partly
or completely filling the compartment, and the foam is also allowed
to degas inside the compartment. This improves the flow of the foam
material during production and improves the homogeneity of the
material setup forming the device. Preferably, the carrier element
has at least one empty compartment, which has at least one opening
being accessible for being entered by the soft foam material during
production of the device.
[0022] Preferably, the carrier element has at least one empty
compartment, which is closed at the bottom and has at least one
opening at the top being accessible for being entered by the soft
foam material during production of the device. This way, the foam
may be guided from the top, potentially connecting the surface
layer and/or the shield element with the vibration decoupling
element, to degas inside the empty compartment.
[0023] Preferably, the shield element is at least in part covering
and/or closing the at least one empty compartment. Preferably, the
shield element has at least one passage section, e.g. an opening,
e.g. a through-hole, which is vertically aligned with the at least
one empty compartment, in particular with an opening or passage
section of the carrier section. Preferably, the at least one second
passage section of the shield element and the at least one empty
compartment are configured to allow the soft foam material pass the
second passage section and to at least partially enter the empty
compartment during production of the device, wherein the empty
compartment, in particular, serves as a degassing space for the
soft foam material.
[0024] Preferably, the at least one passage section of the carrier
element, the at least one passage section of the shield element,
the at least one second passage section of the shield element and
the at least one empty compartment are configured to allow the soft
foam material to pass the at least one passage section of the
carrier element, the at least one passage section of the shield
element, the at least one second passage section of the shield
element and to at least partially enter the empty compartment
during production of the device, wherein the empty compartment, in
particular, serves as a degassing space for the soft foam
material.
[0025] Preferably the shield element has at least one integrated
protrusion that aligns with at least one indentation or recess in
the carrier element to clip the shield element on the carrier
element and to prevent it from moving during the application of the
soft foam.
[0026] Preferably, the shield element is configured to serve as a
support and impact zone for the support bar of a child seat in a
motor vehicle, which may be mounted to the vehicle by a commercial
ISOFIX system. The device may include a mounting socket for
mounting the stand, which supports the child seat against floor pan
via the device according to the invention.
[0027] The invention, furthermore, relates to a method for
producing the device according to the invention. The method
according to the invention for producing a device for at least
partially covering a vehicle floor pan of a motor vehicle,
comprises the steps: --providing a carrier element made at least by
a hard foam material; --providing a vibration decoupling element
made at least by a soft foam material; --providing a surface layer
to visually cover the device from the top; providing a shield
element, which is made at least by a plastic material and is
configured for accepting, absorbing and distributing the energy of
a localized impact stress, which is applied on the device from
above against the shield element; --assembling said components for
providing the device. The method, in particular may include the
step of applying a reaction injection molding process to provide
the vibration decoupling element, and, preferably to connect at
least two or all of the components of the device.
[0028] Further embodiments of the device and the method according
to the invention may be derived from the description of the
embodiments shown in the figures and from the figures.
FIGURES AND FURTHER EMBODIMENTS
[0029] FIG. 1 shows a cross section of a device according to a
first embodiment of the invention.
[0030] FIG. 2 shows a cross section of the device according to a
second embodiment of the invention.
[0031] FIG. 3 shows a cross section of the device according to a
third embodiment of the invention.
[0032] FIG. 4 shows a cross section of the device according to a
fourth embodiment of the invention.
[0033] FIG. 5 shows a cross section of the device according to a
fifth embodiment of the invention.
[0034] FIG. 6 shows a cross section of the device according to a
sixth embodiment of the invention.
[0035] FIG. 7a shows a top view on the shield element, which can be
used with a device according to the invention.
[0036] FIG. 7b shows a cross section of the shield element in FIG.
7a along the line A.
[0037] FIG. 8a shows a shield element, which can be used with the
device according to the invention.
[0038] FIG. 8b shows a cross section of the shield element in FIG.
8a along the line A.
[0039] FIG. 9 shows the top view of a shield element, which can be
used with the device according to the invention.
[0040] FIG. 10 shows the top view of another shield element, which
can be used with the device according to the invention.
[0041] FIG. 11a shows the top view of another shield element, which
can be used with the device according to the invention.
[0042] FIG. 11 b shows a cross section of the shield element in
FIG. 11 a along the line A.
[0043] FIG. 12a shows in the top view of another shield element,
which can be used with the device according to the invention.
[0044] FIG. 12b shows a cross section of the shield element in FIG.
12a along the line A.
[0045] FIG. 13 shows a cross section of a device according to the
seventh embodiment of the invention.
[0046] FIG. 14 shows the arrangement of a baby seat in a motor
vehicle and a device according to the invention, wherein the back
craft of the baby seat is supported by a stand, which is placed on
the device according to the invention.
[0047] FIG. 15 shows a cross section of a device according to the
eights embodiment of the invention.
[0048] FIG. 16 shows a cross section of a device according to the
ninth embodiment of the invention.
[0049] FIG. 1 shows the device 1 for at least partially covering a
vehicle floor pan of a motor vehicle. The device 1 comprises a
carrier element (2; 22, 42; 62; 82; 102; 122). In the embodiment of
FIG. 1, the carrier element has the shape of substantially a
rectangular plate, which is appropriate for being arranged in
parallel to a vehicle floor pan of a motor vehicle. The carrier
element 2 is made from a hard foam material, which is EPS, in the
embodiment of FIG. 1. The device also comprises a vibration
decoupling element 3, which is made from a soft foam material, in
the embodiment of FIG. 1. The soft foam material is open-cell
polyurethane. Such a material has sufficient sound absorbing
capacities, and can be used also for the other embodiments of the
device according to the invention
[0050] The device 1 is covered from above by a surface layer 4,
which is a carpet in the embodiment of FIG. 1. The carpet may be a
tufting carpet, which may be provided with a sheet member 7, e.g. a
plastic foil, which is arranged between the vibration decoupling
element 3 and the surface layer 4. Such a plastic foil 7 or other
sheet member may be used in order to prevent that the foam raw
material, which forms the vibration decoupling element during a
process of foam injection molding, would bleed through the surface
layer 4 and thereby would impair the visual appearance of the
device. The sheet member 7 may be provided with pores or
micropores, in order to allow the air to penetrate the sheet member
7 or even to allow a predetermined amount of foam raw material 3 to
penetrate the sheet member and proceed inside of the surface layer
4, without penetrating the surface layer 4.
[0051] The device 1 also has a shield element 5, which is made from
a plastic material. The plastic material is polypropylene, in the
embodiment of FIG. 1. The shield element 5 is--or comprises--a
substantially plain plate 5, which is arranged in parallel to the
carrier element 2. The plate may be or contain a grid composed of
interconnected ribs. This can significantly enhance the stiffness
and the loading capability of the shield element. The shield
element 5 is placed above the upper side of the carrier element 2,
wherein the carrier element 2 and the shield element 5 are
connected with each other by the soft foam material, which forms
the vibration decoupling element 3. In the present case, both, the
carrier element 2 and the shield element 5, are completely
surrounded by the foam material of the vibration decoupling element
3.
[0052] The shield element 5 serves for accepting, absorbing and
distributing the energy of a localized impacts stress, which is
applied on the device from above against the shield element 5.
Typically, such a shield element is required, when the backrest of
a baby seat has to be supported on the vehicle floor in the
passenger compartment of a motor vehicle. For such application
scenarios, a predetermined load capacity of the device is required
in order to safely prevent the baby seat from leaving the mounting
position inside the motor vehicle during a possible crash of the
motor vehicle.
[0053] Furthermore, the shield element 5 has the technical function
of serving as a mass element for the vibration decoupling system,
which is represented by the device for covering the vehicle floor
pan of a motor vehicle. The shield element 5 serves as the mass in
a mass-spring-system, which is realized by such a vibration
decoupling system, because the mass density of the shield element 5
is significantly higher than the mass density of the soft foam
element 3, which forms the spring in the mass-spring-system.
[0054] The shield element 5 has one passage section 5a, which is
configured for allowing at least a certain amount of the soft foam
material to pass inside or through the shield element 5 during the
production of the device. The passage section 5a is a cylindrical
opening here, which extends vertically from the bottom side to the
top side of the shield element, thereby forming a through-hole in
the shield element. During the foam injection molding process, the
foam raw material penetrates the hole 5a and connects the surface
layer 4 with the shield element 5 and the carrier element 2.
[0055] The device 24, for partially covering on the vehicle floor
pan of a motor vehicle, shown in FIG. 2, has a carrier element 22.
The carrier element 22 has a plate section 22d, which is, in the
embodiment, integrally formed with projections 22c, which extend
from the plate section 22d vertically downwards. The projections
22c carry the load, which is applied on the device 20. Between the
projections 22c, one or multiple empty compartments 22b are formed.
Such compartments are: either, respectively, closed at all sides
except their bottom side, where they are opened; or, respectively,
interconnected to form an interconnected empty space between the
projections 22c beneath the plate section 22d of the carrier
element. Such empty compartments are typical for a false floor
component, which is realized by the device of FIG. 2. The surface
layer 24, which may form the visual floor in the passenger
compartment of a motor vehicle, is elevated and supported by the
carrier element. Such a false floor is preferably configured to
even out any height differences of the underlying floor pan.
[0056] The carrier element 22 is embedded in a vibration decoupling
element 23, which is made from an open-cell polyurethane soft foam
material. The vibration decoupling element 23, in the embodiment of
FIG. 2, substantially surrounds the hole carrier element 22 and
preserves the basic shape of the same, which is formed by an upper
plate, supported on projections, which extend vertically downwards.
Thereby, also the empty compartments 22b are preserved, even though
they may be in part or completely filled with soft foam material.
The shield element 5, made from polypropylene, is placed above the
upper side of the carrier element 22. The shield element 25 has two
or more holes 25a, which allow the soft foam material 23 to pass
through the shield element during the production of the device.
[0057] The device 40 for at least partially covering the floor pan
of a motor vehicle, shown in FIG. 3, substantially has the same set
up as the device 20 shown in FIG. 2. The carrier element 42 has a
plate section, with projections 42c being connected to the plate
section and extending vertically downwards therefrom. Empty
compartments 42b are formed between the projections 42c. The
compartments 42b are open at least at their bottom. As a difference
to the device of FIG. 2, the device 40 has empty compartments 42b'
which are extending from the upper side of the carrier element 24
vertically downwards inside the carrier element 42. The empty
compartments 42b' are closed, except from their upper side, where
they are open. The upper side faces the surface layer 44.
[0058] In the embodiment of FIG. 3, the empty compartments 42b'
extend, respectively, inside one of the projections 42c, which
extend vertically downward from the plate section of the carrier
element 42. Thereby, at least one or a plurality of the protections
42c are hollow projections, also referred to as domes, which are
filled with air and which may be in part filled with foam raw
material 43a.
[0059] The empty compartments reduce the weight of the device
according to the invention and reduce the amount of material, which
is required to form the device. Moreover, the empty compartments
42b' allow the foam material 43a to enter the empty compartments
42b' by a certain amount 43a, wherein the foam raw material 43a is
allowed to degas during the process of foam injection molding
inside the empty compartments. The shield element 45 covers at
least a part of the carrier element 42 and is in direct contact
with the carrier element 42. The shield element 45 has a plurality
of holes 45a, which are aligned with the openings at the upper side
of the empty compartments 42b'. The shield element 45 respectively
closes the opening of the compartments 42b'. Therefore, a hole 45a
forms the only entry opening for a hollow compartment 42b' for the
embodiment of FIG. 3, such that the foam raw material may pass
through the holes 45a and through the opening of the upper side of
the empty compartments 42b' during the foam injection molding of
the device. By way of the holes 45a, the foam is allowed to
reliably distribute along the shield element 45 and to connect the
shield element 45 with the carrier element 42, while the soft foam
material is allowed to degas inside the empty compartments
42b'.
[0060] The device 40 offers sufficient stability against impact
loads, which may be directed against the shield element 45. The
empty compartments 42b and 42b' contribute to the light-weight
property of the device 40, wherein the carrier element 42
sufficiently supports the shield element 45, the surface layer 44,
and any loads acting on the shield element 45. At the same time,
the vibration decoupling element 43 provides sufficient vibration
decoupling capability to the device.
[0061] In FIG. 4, the device 60 is formed similar to the device 40
shown in FIG. 3, having a carrier element 62 with a base plate and
projection 62c, empty compartments 62b opening to the bottom side
and empty compartments 62b', opening to the upper side of the
carrier element 62. However, in contrast to the carrier element 42,
the carrier element 62 has an opening 62a, which is a through-hole
extending from the bottom side of the carrier element 62 to the
opposing upper side. The shield element 65 is a plain plate, in the
embodiment, and covers the carrier element 62 at least in part and
is in direct contact with the same. The shield element 65 follows
the upper surface profile of the carrier element 62, similar to all
other embodiments of the device in FIGS. 1 to 6 and 13. Thereby,
the shield element 65 is supported by a possibly large contact
surface at the carrier element 62.
[0062] Openings 65a of the shield element 65, formed as
through-holes, are aligned with empty compartments 62b', which
extend from their respective opening at the upper side of the
carrier element 62 vertically downward inside the carrier element.
Moreover, at least one opening 65a of the shield element is aligned
with a through-hole 62a of the carrier element 62. Thereby, the
foam raw material 63 is allowed to flow during the injection
molding along the direction of the arrow 66 through the opening 62a
and through the center hole 65a upwards, thereby reaching the area
between the carpet 64 and the shield element 65. From there, the
foam raw material can flow laterally and enter the empty
compartments 62b' through the holes 65a of the shield element. The
empty compartments 62b' act as a space reservoir and as expanding
zones for the foam raw material, which is allowed to expand into
the compartments along the direction of arrow 66a to form a piece
of foam 63a and to degas inside the compartment. As a consequence,
the layer of foam 63 between the shield element 65 and the carpet
64 is homogeneously distributed, and the carpet 64, the shield
element 65 and--via the foam element 63a--the carrier element are
adhered to each other by the foam 63.
[0063] The device 60 offers sufficient stability against impact
loads, which may be directed against the shield element 65. The
empty compartments 62b and 62b' contribute to the light-weight
property of the device 60, wherein the carrier element 62
sufficiently supports the shield element 65, the surface layer 64,
and any loads acting on the shield element 65. At the same time,
the vibration decoupling element 63 provides sufficient vibration
decoupling capability to the device.
[0064] In FIG. 5, the device 80 is formed similar to the device 60
shown in FIG. 4, having a carrier element 82 with a base plate and
projection 82c, empty compartments 82b opening to the bottom side
and empty compartments 82b', opening to the upper side of the
carrier element 82 and a through-hole 82a. However, in contrast to
the carrier element 62, the empty compartments 82a' of the carrier
element 82, which extend from the upper side of the carrier element
82 vertically downwards inside the protrusions 82c, have openings
82d at their bottom side, which connect the inside of the domes 82c
with the bottom side of the device 80. Therefore, the compartments
82a' form an end-to-end connection between the upper side and the
bottom side of the carrier element 82 and lead vertically
throughout the whole height of the carrier element 82. Foam raw
material 83 may pass through the openings 82d, for example from
outside to inside of the domes 82c, thereby forming foam pieces 83b
inside the domes, where the foam may expand and degas. The foam may
also completely fill the domes 83c here (not shown). The foam piece
83b also increases the connection between the vibration decoupling
element 83 with the carrier element 82 at the bottom side of the
same.
[0065] The device 80 offers sufficient stability against impact
loads, which may be directed against the shield element 85. The
empty compartments 82b and 82b' contribute to the light-weight
property of the device 80, wherein the carrier element 82
sufficiently supports the shield element 85, the surface layer 84,
and any loads acting on the shield element 85. At the same time,
the vibration decoupling element 83 provides sufficient vibration
decoupling capability to the device.
[0066] In FIG. 6, the device 100 is formed similar to the device 60
shown in FIG. 5, having a carrier element 102 with a base plate and
projection 102c, empty compartments 102b, which open to the bottom
side, and empty compartments 102b', which open to the upper side of
the carrier element 102 and a through-hole 102a. However, in
contrast to the carrier element 62, the compartment 102a of the
carrier element 102, which was empty before the foam injection
molding, was completely filled with foam 103. The opening 102a
serves as a channel for the foam, which flows through the channel
102a vertically upwards through the hole 105a of the shield element
105, along the arrow 106, entering the space between the surface
layer 104 and the shield element 105, where the foam distributes in
lateral directions and enters the domes 82c along the arrow 86a,
eventually expanding and degassing inside the domes 82c, and
forming a foam piece 103a inside the dome, which also interconnects
the carrier element 102 with the shield element 105 and the further
components of the device 100.
[0067] The device 100 offers sufficient stability against impact
loads, which may be directed against the shield element 85. The
empty compartments 102b and 102b' contribute to the light-weight
property of the device 100, wherein the carrier element 102
sufficiently supports the shield element 105, the surface layer
104, and any loads acting on the shield element 105. At the same
time, the vibration decoupling element 103 provides sufficient
vibration decoupling capability to the device.
[0068] FIGS. 7a and 7b shows a shield element, which may be used as
a part of the device according to the invention. The shield element
5 is a simple rectangular cuboid plate, here, but may be formed
different, in order to be adapted to any desired shape of a device.
The shield element 5 has a number N of through-holes 5a, N=4 in the
present case.
[0069] The shield element 5' in FIGS. 8a and 8b is also formed
similar to be a substantially rectangular cuboid plate. It has a
number N of througholes, here N=2. The shield element 5',
furthermore, has a channel section 5b', which extends parallel to
the plate in the upper side of the shield element 5' and which
connects the through-holes by an empty space. The latter may be
filled with foam raw material, which may be forced to flow from the
first opening through the channel 5b' and through the second
opening 5a'. The channel allows the distribution of foam raw
material. This is even possible, if a--here plain--surface layer of
the device is placed directly on top of the upper side of shield
element 5'.
[0070] The shield element 5'' in FIG. 9 is also formed to be a
substantially rectangular cuboid plate. It has a number N of
recesses, which form vertically oriented ports along a lateral side
of the shield element 5'', here N=2. Such ports allow the foam
material to progress from the lateral sides of the shield element
to also reach the central regions of the upper or bottom side of
the shield element.
[0071] The shield element 5''' in FIG. 10 is also formed to be a
substantially rectangular cuboid plate. It has a number N of
recesses, which form vertically oriented ports along a lateral side
of the shield element 5''', here N=4. Similar to FIG. 8a, 8b, the
shield element has channel sections 5b''', which crosswise
intersect at a center point and which interconnect the pairwise
opposing through-holes 5a'''. The channels 5b''' allows the
distribution of foam raw material. This is even possible, if
a--here plain--surface layer of the device is placed directly on
top of the upper side of shield element 5'.
[0072] Shield element 5'''' shown in FIG. 11a and 11b is similar to
shield element 5 in FIG. 7a, 7b, but has an additional through-hole
5a'''' in the center of a virtual cross, which has an opening
5a'''' at each end of the crossbars.
[0073] Shield element 125 shown in FIG. 11a and 11b is similar to
shield element 5''' in FIG. 10, but has an additional through-hole
125a in the center of a virtual cross, which has an opening 125a at
each end of the crossbars. The channels 125b allows the
distribution of foam raw material. This is even possible, if
a--here plain--surface layer of the device is placed directly on
top of the upper side of shield element 125.
[0074] Shield element 125 is used in the device 120, shown in FIG.
13. The device 120 corresponds identical to the device 100 in FIG.
6, except from the embodiment of the shield element. In FIG. 6, a
shield element 5''' is used; in FIG. 13 with device 120, the shield
element 125 is used, which allows to directly place shield element
125 on top of carrier element 122 in direct contact with the same.
The channels 125b allows the distribution of foam raw material.
This is even possible, if a--here plain--surface layer of the
device is placed directly on top of the upper side of shield
element 125, as is the case in FIG. 13.
[0075] The device 120 offers sufficient stability against impact
loads, which may be directed against the shield element 85. The
empty compartments 122b and 122b' contribute to the light-weight
property of the device 120, wherein the carrier element 122
sufficiently supports the shield element 125, the surface layer
124, and any loads acting on the shield element 125. At the same
time, the vibration decoupling element 123 provides sufficient
vibration decoupling capability to the device.
[0076] FIG. 14 shows an arrangement 200 including a device 1
according to the invention -any other device according to the
invention may alternatively used. The arrangement also may include
a socket 8 and a stand 204, which rests on top of the socket. The
socket 8 is placed on top of the surface layer 4, and on top of the
shield element 5. The socket may be a part of the device 1, or any
device according to the invention, and may be connected to the
device. Alternatively, the socket may not be a part of the device,
but may be a separate part, which may also be connected to the
stand 204. The stand 204 serves to safely support the backrest of a
baby seat 203, which is also partly supported by a rear bench seat
202 or a co-driver's seat 202 of a motor vehicle. The baby seat may
be connected in the car via a commercial ISOFIX system. The device
1, and any other device according to the invention, is preferably
configured to be used as a support for the stand of a babyseat, as
shown in FIG. 14.
[0077] The device 1, furthermore, is also adapted to balance height
differences between the floor pan 201 and with adjacent sections
201a of the floor pan, which have increased height.
[0078] In FIG. 15, the device 140 for at least partially covering a
vehicle floor pan of a motor vehicle, comprises a carrier element
142 made at least by a hard foam material, a sound dampening
element 143 made at least by a soft foam material, a surface layer
144 to visually cover the device from the top, wherein the device
has a shield element 145, which is made at least by a plastic
material and is configured for accepting, absorbing and
distributing the energy of a localized impact stress, which is
applied on the device from above against the shield element. The
shield element 145 has a first section with through-hole 145a,
which is deposited at least in part vertically above the first
section of the carrier element 142. The shield element 145 has a
second section with through-hole 145a, which is deposited at least
in part vertically above the second section of the carrier element
142. The first and second sections of the shield element 145 may be
separate parts or may be an integral part, having an opening at the
position of the empty recess 143a. Between the first section of the
carrier element and the second section of the carrier element,
there is the empty recess 143a, which may be designed for receiving
any additional components of the device or of a vehicle, e.g.
cables. An additional shield element 1415, e.g. made at least in
part or completely from plastic, covers the empty recess 143a and
is supported by the first and second sections of the shield element
145, wherein the additional shield element 1415 is configured for
accepting, absorbing and distributing the energy of a localized
impact stress, which is applied on the device from above against
the shield element, in combination with shield element(s) 145.
[0079] In FIG. 16, a similar embodiment compared to FIG. 15 is
shown, with corresponding reference signs. Here, the first and
second sections of the carrier element 162 has through-holes 162a,
respectively aligned with through-holes 165a of the first and
second sections of the shield element 165, wherein the
through-holes serve to let the foam raw material pass during the
process of foam injection molding, thereby connecting the
components of the device 140, 160.
[0080] In FIG. 15, the device 140 for at least partially covering a
vehicle floor pan of a motor vehicle, comprises a carrier element
142 made at least by a hard foam material, a sound dampening
element 143 made at least by a soft foam material, a surface layer
144 to visually cover the device from the top, wherein the device
has a shield element 145, which is made at least by a plastic
material and is configured for accepting, absorbing and
distributing the energy of a localized impact stress, which is
applied on the device from above against the shield element. The
shield element 145 has a first section with through-hole 145a,
which is deposited at least in part vertically above the first
section of the carrier element 142. The shield element 145 has a
second section with through-hole 145a, which is deposited at least
in part vertically above the second section of the carrier element
142. The first and second sections of the shield element 145 may be
separate parts or may be an integral part, having an opening at the
position of the empty recess 143a. Between the first section of the
carrier element and the second section of the carrier element,
there is the empty recess 143a, which may be designed for receiving
any additional components of the device or of a vehicle, e.g.
cables. An additional shield element 1415, e.g. made at least in
part or completely from plastic, covers the empty recess 143a and
is supported by the first and second sections of the shield element
145, wherein the additional shield element 1415 is configured for
accepting, absorbing and distributing the energy of a localized
impact stress, which is applied on the device from above against
the shield element, in combination with shield element(s) 145.
[0081] In FIG. 16, a similar embodiment compared to FIG. 15 is
shown, with corresponding reference signs. Here, the first and
second sections of the carrier element 162 has through-holes 162a,
respectively aligned with through-holes 165a of the first and
second sections of the shield element 165, wherein the
through-holes serve to let the foam raw material pass during the
process of foam injection molding, thereby connecting the
components of the device 140, 160.
* * * * *